Hard magnetic materials

ABSTRACT

Fine-grained sintered magnetic material having the composition expressed by SmMz where M is essentially cobalt or a combination of cobalt, iron and copper, exhibits a large coercive force critically when the z-value is in the vicinity of 8. As small amount of zinc can be added to the raw material to aid in the sintering of the material.

This is a continuation, of application Ser. No. 651,596, filed Jan. 22, 1976, now abandoned.

An object of the present invention is to provide a novel and improved hard magnet material having improved superior magnetic characteristics, especially exceedingly high coercive force, and this is realized with a composition of RM_(z), where R consists essentially Sm or a combination of Sm and Pr, M consists essentially Co or a combination of Co, Fe and Cu, and z is about 8.0.

BRIEF DESCRIPTION OF THE DRAWINGS

This and other objects and features of the invention will be apparent from consideration of the following detailed description of the invention with accompanying the drawings in which:

FIG. 1 is a graph showing intrinsic coercive force (for sintered specimens having compositions of about Sm(Co₀.85 Fe₀.05 Cu₀.10)_(z)) as a function of z value.

FIG. 2 shows intrinsic coercive force, average grain size and density as function of a sintering time at sintering temperature of 1230° C for cast bodies of sintered specimens of this invention having the nominal composition of about Sm(Co₀.83 Fe₀.05 Cu₀.1)₈.0 .

FIG. 3 shows intrinsic coercive force for other specimens having the nominal composition of Sm(Co₀.83 Fe₀.05 Cu₀.1)₈.0 as function of a sintering temperature at a sintering time of 30 minutes.

DETAILED DESCRIPTION OF THE INVENTION

The hard magnetic material of the invention is most suitably described in terms of a general composition formula RM_(z), where R represents rare earth elements, most preferably Sm, and M means essentially Co or a combination of Co, Fe and Cu. The inventors have found that the said composition when subjected to sintering exhibits an unexpectedly large coercive force when the z value is close to 8.0. The dependence of coercive force on the z value is very critical, and this will be understood from the following examples.

EXAMPLE 1

Alloys were prepared by melting ingredient metals in proper ratio so as to provide nominal composition of about Sm(Co₀.83 Fe₀.05 Cu₀.10 Zn₀.02)₈.0. Chemical analysis of several resultant specimens were as shown below.

    ______________________________________                                                     Content(wt.%)                                                      Specimen No.      Sm     Co   Fe  Cu  Zn    Total                              ______________________________________                                         Z3       as cast  24.4   62.1 3.9 8.1 1.1   99.6                               Z6       as cast  24.0   62.5 3.9 8.2 1.1   99.7                                        sintered 24.2   63.1 3.8 8.2 <0.1  99.4                                Z12     as cast  23.5   62.6 4.0 8.0 1.1   99.2                               ______________________________________                                    

For example, the sintered specimen No. Z6 can be expressed by the formula Z6 .tbd. Sm(Co₀.843 Fe₀.053 Cu₀.101 Zn₀.001)₇.92 if other impurities not analyzed are not considered. However, chemical analysis of the absolute value of Sm content may be up to 0.5% in error. It should be noted that Zn hardly exists in a sintered body suggesting the fact that Zn evaporates off during sintering. Relative amounts of Sm to the rest of the composition of these alloys were determined from the intensity of characteristic X-ray of Sm by means of X-ray fluorescent analysis. The results were as shown below.

    ______________________________________                                                        Relative amounts of Sm                                          Specimen No.   (Arbitrary Unit)                                                ______________________________________                                         Z3             1.1746                                                          Z4             1.1751                                                          Z5             1.1643                                                          Z6             1.1527                                                          Z8             1.1561                                                          Z9             1.1379                                                           Z10           1.1472                                                           Z12           1.1179                                                           Z13           1.1443                                                           Z14           1.1230                                                          ______________________________________                                    

The relative amount of Sm is most accurately determined in this way, although absolute value of the amount of Sm can not be determined.

The alloys were crushed into coarse grains and then pulverized into fine powders whose average size was about 3 micron by jet milling. The powders were pressed in a magnetic field at 15KOe and were further compacted into green bodies by means of an isostatic pressing of about 3 tons/cm². The thus compacted bodies were sintered in vacuum of 5 × 10⁻⁵ mmHg for 25 or 30 minutes at various temperatures between 1125°-1260° C. The best values of coercive force of the resultant sintered bodies were obtained at the sintering temperature of about 1240° C. FIG. 1 shows the best values of coercive force plotted against the z value.

Chemical analysis showed that almost all of the Zn evaporated off during the sintering. The addition of small amount of Zn has an effect of promoting the sintering thus resulting in a better shrinkage of the specimens, although the final sintered products do not contain significant amounts of Zn.

FIG. 2 shows intrinsic coercive force, average grain size and density of the resultant sintered specimens having the nominal composition of Sm(Co₀.83 Fe₀.05 Cu₀.1 Zn₀.02)₈.0 as function of a sintering time at a sintering temperature of 1230° C.

EXAMPLE 2

The powders corresponding to Z12 and Z4 of Example 1 were mixed in a proper ratio so as to provide the Z6 composition. The mixed powders were subjected to the same process as that of Example 1, and the resultant sintered bodies exhibited a coercive force between 5,000 and 8,000 Oe which was essentially the same as the optimum value of the coercive force in Example 1.

EXAMPLE 3

Specimens of Z17, Z18, Z19 and Z20 with nominal compositions of about sm(Co₀.83 Fe₀.05 Cu₀.10)₈.0 were prepared by the same method as that of Example 1. Relative amounts of Sm in these specimens are tabulated below in the same unit as that of Example 1. The results are summarized as follows.

    ______________________________________                                         Speci-                                                                               Relative amount                                                                             Sintering  Sintering                                        men   of Sm        temperature                                                                               time   I.sup.H c                                 No.   (Arbitrary Unit)                                                                            (° C)                                                                              (min.) (Oe)                                      ______________________________________                                         Z17   1.1216       1190       30      1900                                     Z18   1.1567       1140       30     14000                                     Z19   1.1724       1140       30     13800                                     Z20   1.1372       1140       30      2400                                     Z21   1.1822       1140       30      600                                      Z22   1.1563       1140       25     14300                                     Z23   1.1349       1140       25     10600                                     Z24   1.1292       1140       25     14100                                     Z25   1.1185       1135       25     12000                                     Z26   1.1363       1140       25      2200                                     Z27   1.1344       1119       25     >15000                                    Z28   1.1314       1125       25     13600                                     ______________________________________                                    

FIG. 3 shows intrinsic coercive force as function of sintering temperature in the specimens of Z19 with a sintering time of 30 minutes. 

What is claimed is:
 1. A sintered magnetic material consisting essentially of samarium, cobalt, iron and copper, said composition being expressed by the formula Sm(Co_(1-x-y) Fe_(x) Cu_(y))_(z), in which x is 0.01 to 0.15, y is 0.05 to 0.15 and z is 7.8 to 8.2, said sintered material having an average grain size less than 10 microns and exhibiting a coercive force of at least about 10,600 Oe. 